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Clark EPG 15-18 Forklift Service Repair Manual.pdf

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This document provides a summary of safe maintenance practices for industrial trucks. It discusses safety signs and messages used in service manuals. Proper ventilation, fire safety, and authorized personnel are important. Before working on a truck, raise the wheels, disconnect the battery, and check for fuel and electrical hazards. Replacements parts must meet manufacturer standards. Modifications require approval. Overall, maintenance should follow manufacturer procedures to ensure safety.

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#40–1, Ungnam-Dong, Changwon-City,Kyungnam, Korea TMG 12-25 TMG13-20X EPG 15-18 Part No. 8026067 Book No. SM-616 REV.2 Dec. 2002 SERVICE MANUAL TMG 12-25 RATED CAPACITY: 1250 – 2270KG EPG 15-18 RATED CAPACITY: 1500 – 1800KG Manufactured by
Contents-ii SM 616, Sep ’02 © Copyright Clark Material Handling Company 2001 This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Maintenance,” and the Operator’s Manual before working on or operat- ing the truck. Page ID Manual ID Group ID Page ID Group ID Section ID Section ID Arrangement and Use of this Manual Clark arranges parts and service procedures by standard- ized Groups. In this manual, Groups are similar to “Chap- ter.” Groups are listed I the table of contents on the next page. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents showing the topics contained within the Section. Each Group and Section has an identifying name and number, or “ID.” Each page also has a unique ID. The page ID consists of three numbers separated by hyphens, year/month and the revision number. The three numbers represent the Group number, the Section number, and the page number. For example, “00-1-2” on the lower corner of the page indi- cates Group 00, Section 1, Page 2. The year/month repre- sent the issued or revised one such as April 98. The revision number indicates the revised frequency such as ➀, ➁ .... If not depicted, the page has not been revised. You can quickly locate a specific point in the manual by using the headers and footers that appear on every Sec- tion page. The following illustration points out these areas.
Contents-iii SM 616, April ’98 SA SAFE MAINTENANCE 1. Safety 2. Lifting, Jacking, and Blocking 3. Towing PS PERIODIC SERVICE 1. Maintenance Schedules 2. Planned Maintenance 3. PM Inspection Form 12 BATTERY 1. Battery Service 13 WIRING, SWITCHES, AND INSTRUMENTS 1. Schematic Diagrams 2. General Electrical Service Tips 3. Wiring and Cables 4. Switches and Sensors 5. Instrument Panel 16 ELECTRIC MOTORS 1. Specifications and Description 2. Troubleshooting 3. Drive Motors Overhaul 4. Lift Pump Motor Overhaul 5. Steering Pump Motor Overhaul 17 CONTACTORS 1. Specifications and Overhaul 19 MOTOR CONTROLS 1. Specifications and Description 2. Sequence of Operations 3. Handset Operation 4. Diagnostic Status Codes 5. Controllers Removal and Replacement 20 DRIVE AXLE 1. Specifications and Description 2. Fluid Check and Change 3. Troubleshooting 4. Drive Axle Removal and Installation 5. Drive Axle Overhaul 22 WHEELS AND TIRES 1. Specifications and Description 2. Wheels & Tires Mounting and Maintenance 23 BRAKE SYSTEM 1. Specifications and Description 2. Fluid Check, Fill, and Bleed 3. Pedal and Master Cylinder Removal, Replace- ment, and Adjustment 4. Brake Removal and Replacement 5. Parking Brake R&R and Adjustment 6. Brake Overhaul 25/26 STEER SYSTEM 1. Specifications and Description 2. Troubleshooting 3. Column Removal and Replacement 4. Relief Pressure Check and Adjustment 5. Steering Gear Overhaul 6. Steer Axle Service 7. Steer Cylinder Overhaul 8. Steer Pump Overhaul 29/30 HYDRAULIC SYSTEM 1. Specifications and Description 2. Fluids and Filters 3. Troubleshooting 4. Pressure Checks and Adjustments 5. Main Pump Removal and Overhaul 6. Main Control Valve Removal and Overhaul 32 TILT CYLINDERS 1. Specifications and Description 2. Checks and Adjustments 3. Removal and Installation 4. Overhaul 34 UPRIGHTS 1. Upright Specifications and Description 2. Trouble shooting 3. Upright Inspection 4. Carriage and Upright Roller Clearance Checks and Shim Adjustment 5. Cylinder Removal, Shimming, Overhaul and Replacement 6. Upright Chain Inspection, Adjustment and Installation 7. Fork and Carriage Removal and Installation 8. Upright Removal and Replacement 38 COUNTERWEIGHT AND CHASSIS 1. Specifications and Description 2. Counterweight Removal and Installation 3. Overhead Guard Removal and Installation 4. Floor Plate, Seat, and Seat Deck R&R 40 SPECIFICATIONS 1. Nameplate and Decals 2. Specifications 3. Hydraulic Fitting Tightening Procedure Contents by Group and Section Contents are listed here by Group number and name followed by Section number and name: CONTENTS (Alphabetical listing of contents appears on next page.)
Contents-iv SM 616, April ’98 Battery Service ......................................................... 12-1 Brake Fluid Check, Fill, and Bleed ......................... 23-2 Brake Overhaul ........................................................ 23-6 Brake Removal and Replacement .......................... 23-4 Brake System Specifications and Description ...... 23-1 Carriage and Upright Roller Clearance Checks and Shim Adjustments.................................................... 34-1 Column Removal and Replacement .................. 25/26-3 Contactors ................................................................ 17-1 Contactors Specifications and Description .......... 17-1 Controllers Removal and Replacement ................. 19-5 Controllers Specifications and Description .......... 19-1 Counterweight Removal and Installation............... 38-2 Counterweight Specifications and Description .... 38-1 Cylinder Removal, Shimming, Overhaul, and Replacement ............................................................. 34-5 Diagnostic Status Codes ......................................... 19-4 Drive Axle Fluid Check and Change ...................... 20-2 Drive Axle Overhaul ................................................. 20-5 Drive Axle Removal and Installation ...................... 20-4 Drive Axle Specifications and Description ............ 20-1 Drive Axle Troubleshooting .................................... 20-3 Drive Motors Overhaul ............................................ 16-3 Electrical Service Tips ............................................. 13-2 Floor Plate Removal and Replacement .................. 38-4 Fork and Carriage Removal and Installation ......... 34-7 Handset Operation ................................................... 19-3 Hydraulic Control Valve Overhaul .....................29/30-6 Hydraulic Fitting Tightening Procedure................. 40-3 Hydraulic Fluids and Filters ............................... 29/30-2 Hydraulic Pressure Checks and Adjustments . 29/30-4 Hydraulic Lift Pump Overhaul............................29/30-5 Hydraulic Specifications and Description ........29/30-1 Hydraulic System Troubleshooting................... 29/30-3 Instrument Panel ...................................................... 13-5 Jacking and Blocking ............................................. SA-2 Lift Chain Inspection and Service Guidelines ....... 34-2 Lift Pump Motor Overhaul ....................................... 16-4 Maintenance Schedules ........................................ PM-1 Motors Specifications and Description ................. 16-1 Motors Troubleshooting .......................................... 16-2 Nameplate and Decals ............................................. 40-1 Overhead Guard Removal and Installation ........... 38-3 Parking Brake R&R and Adjustment ...................... 23-5 Pedal and Master Cylinder R&R and Adjustment . 23-3 Planned Maintenance ............................................ PM-2 PM Inspection Form ............................................... PM-3 Safety ....................................................................... SA-1 Schematic Electrical Diagrams ............................... 13-1 Seat and Seat Deck Removal and Replacement ... 38-4 Sequence of Operations .......................................... 19-2 Specifications and Description ......................... 25/26-1 Specifications for Entire Truck ............................... 40-2 Steer Axle Service ...............................................25/26-6 Steer Cylinder Overhaul ..................................... 25/26-7 Steer Pump Overhaul .........................................25/26-8 Steering Gear (Valve) Overhaul ......................... 25/26-5 Steering Pump Motor Overhaul .............................. 16-5 Steering Relief Pressure Check and Adjust ..... 25/26-4 Switches and Sensors ............................................. 13-4 Tilt Cylinders Checks and Adjustments ................ 32-2 Tilt Cylinders Overhaul ............................................ 32-4 Tilt Cylinders Removal and Installation ................. 32-3 Tilt Cylinders Specifications and Description ....... 32-1 Towing...................................................................... SA-3 Troubleshooting ......................................... 25/26-2/34-2 Upright Chain Inspection, Adjustment and Installation ......................................................... 34-6 Upright Inspection ................................................... 34-3 Upright Removal and Replacement ....................... 34-8 Upright Specifications and Description ................. 34-1 Wheels & Tires Mounting and Maintenance .......... 22-1 Wheels & Tires Specifications and Description .... 22-1 Wiring and Cables .................................................... 13-3 Alphabetical Listing of Topics (Contents are listed by order of Group and Section numbers on previous page.) Contents are listed here by topic followed by the Group#-Section# the topic appears in:
GROUP SA Safe Maintenance SM 616, April ’98 Safety ............................................................................... Section 1 Lifting, Jacking, and Blocking the Truck ..................... Section 2 Towing.............................................................................. Section 3 GROUP SA SAFE MAINTENANCE
SM 616, April ’98 Safety • SA-1-1 Group SA, Safe Maintenance Section 1. Safety Safety Signs and Messages Safety signs and messages in this manual and on the lift truck provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. NOTE This message is used when special informa- tion, instructions or identification is re- quired relating to procedures, equipment, tools, pressures, capacities, and other spe- cial data. IMPORTANT This message is used when special precau- tions should be taken to ensure a correct action or to avoid damage to, or malfunc- tion of, the truck or a component. CAUTION This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken. WARNING This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. DANGER This message is used when an extreme haz- ard exists that can result in injury or death or serious injury if proper precautions are not taken. The above terms have been adopted by Clark Material Handling Company. The same terms may be used in differ- ent context in service literature supplied directly or indi- rectly by vendors of truck components. Safe Maintenance Practices The following instructions have been prepared from cur- rent industry and government safety standards applicable to industrial truck operation and maintenance. These rec- ommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of in- dustrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Care- fully read and understand these instructions and the spe- cific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please con- tact your local Clark dealer. 1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable mainte- nance facilities, trained personnel, and procedures must be provided. 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. 3. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. Only trained and authorized personnel shall be permit- ted to maintain, repair, adjust, and inspect industrial trucks. Work should be performed in accordance with the manufacturer’s specifications. 5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry. 6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level or leakage of fuel, electrolyte, oil, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Before starting work on truck: a. Raise drive wheels off of floor and use blocks or other positive truck positioning devices. b. Disconnect battery before working on the electri- cal system. 8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed. 9. Operation of the truck to check performance must be
SM 616, Jul ’01 SA-1-2 • Safety Group SA, Safe Maintenance conducted in an authorized, safe, clear area. 10. Before starting to drive truck: a. Be in operating position with seat belt fastened. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed con- trols, steering, brakes, warning devices, and any load handling attachments. 11. Before leaving truck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Stop the engine by turning off the key switch. e. Put upright in vertical position and fully lower the forks or attachment. f. Put blocks at the wheels if truck is on an incline. 12. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety de- vices, and frame members must be carefully and regu- larly inspected and maintained in a safe operating condition. 13. Special trucks or devices designed and approved for hazardous area operation must receive special atten- tion to ensure that maintenance preserves the original, approved, safe-operating features. 14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. 15. The truck manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition. 16. Batteries, motors, controllers, limit switches, protec- tive devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation. 17. To avoid injury to personnel or damage to the equip- ment,consultthemanufacturer’sproceduresinreplac- ing contacts on any battery connection. 18. Industrial trucks must be kept in a clean condition to minimizefirehazardsandhelpinthedetectionofloose or defective parts. 19. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, op- eration and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. 20. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts. 21. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equip- ment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal. NOTE You should also be familiar with additional operating and maintenance safety instruc- tions contained in the following publica- tions: ASME B56.1 - 1988: Operator Control-Industrial Tow Trac- tors (Safety Standard For Powered Industrial Trucks). Pub- lished by: American Society of Mechanical Engineers, Three Park Avenue, New York, NY10016. NFPA 505-1982: Fire Safety Standard for Powered Indus- trial Trucks: Type Designations, Areas of Use, Mainte- nance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. General Industrial Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materials Handling and Storage, Section 1910.178 Powered Indus- trial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
SM 616, April ’98 Lifting, Jacking, and Blocking • SA-2-1 Group SA, Safe Maintenance Section 2. Lifting, Jacking, and Blocking WARNING Lifting or jacking any large piece of equipment such as a fork truck presents obvious hazards. It must be done with great care and fore- thought. Consult the truck weight information in Group 40, Specifica- tions, to ensure that your lifting equipment is of adequate capacity. Raising Drive Wheels.....................................................................................................................2 Chaining the Upright in Raised Position .....................................................................................2 Raising Rear of Truck ...................................................................................................................3 Raising Entire Truck .....................................................................................................................4 Shipping Tie-Down Instructions...................................................................................................4
SM 616, April ’98 SA-2-2 • Lifting, Jacking, and Blocking Group SA, Safe Maintenance CAUTION To perform these service procedures, first: • Park truck on a level surface. • Put the upright in a vertical position and lower the carriage fully down. • Return control handle to neutral and turn key switch OFF. WARNING Defective equipment can cause accidents. All tools and lifting equipment must be in good condition, meet the load capacity requirements and have OSHA labels when required. Tools with defects can fail, causing severe injury or death. Raising Drive Wheels This procedure uses the upright to lift the drive wheels off the floor. 1. Park the truck safely. 2. Turn key switch ON. Tilt the upright fully back. 3. Put a solid 100 x 100 mm (4 x 4 inch) hardwood block under the front section of each upright rail. Put a 3–6 mm (0.125–0.250 inch) steel plate on top of each block. 4. Tilt the upright fully forward. This will raise the drive wheels off the floor. 5. Block the truck under the frame behind the drive wheels with solid blocking. 6. Turn key switch OFF. Blocking a Typical Upright 7. Check for safe clearance between drive wheels, block and floor. 8. Check the stability of the truck. Be sure that the blocks are located securely under the frame before operating the drive motor or working on truck. 9. Lower the drive wheels to the floor by reversing this procedure. • Turn key switch ON. • Tilt upright fully back. • Turn key switch OFF. 10. Remove the blocks from under the frame and upright rails. Chaining the Upright in Raised Position This procedure provides safe clearance for access from the front of truck to components on or near the drive axle. 1. Park truck safely. 2. Put blocks at front of and rear of drive wheels. 3. Raise upright carriage. 4. Chainthecenterinnerrailtiebartothetopouterrailtie bar as shown. Triple Stage Uprights: Chain the center intermediate rail tie bar and the lower inner rail tie bar to the top outer rail tie bar. 5. Reverse the procedure to remove the chains. WARNING Keep hands, tools, etc. out of upright.
SM 616, April ’98 Lifting, Jacking, and Blocking • SA-2-3 Group SA, Safe Maintenance Raising Rear of Truck The truck may be raised at the rear by jacking and blocking under the frame just beyond the counterweight.. Refer to truck data plate for truck weights. WARNING An incorrectly installed counterweight can move or fall unexpectedly. NEVER LIFT OR BLOCK A TRUCK USING THE COUNTERWEIGHT. Failure to follow procedures outlined in this manual can result in injury or death. 1. Park truck safely. 2. Put blocks at front and rear of drive wheels. CAUTION If possible, remove the battery from truck to reduce weight for added safety and ease of jacking. 3. Put a floor jack under the frame just beyond the counterweight. WARNING Never lift the truck by the counterweight. NOTE If there is insufficient clearance under frame for your jack, the truck may first be driven onto shims, such as 25 x 150 x 300 mm (1 x 6 x 12 in) pieces of board, to increase the truck frame under-clearance. 4. Jack up one side of the truck about 50 mm (2 in) and putablockundertheframetoholdthatelevation.Then move the jack to the other side and jack and block it. Continue to alternate the procedure from side to side, increasing elevation not more than 50 mm (2 in) each time. Raise the truck no higher than necessary to perform the maintenance work. Makesuretheleftandrightsidesofthetruckarefinally blocked in a level working position. CAUTION Before performing any maintenance work, check the truck for stable condition on the blocking by determining that it will not rock on blocks. 5. When maintenance work is completed, lower the rear of truck to the floor by reversing the above procedure and lowering each side of the truck 50 mm (2 in) at a time: • Put jack under frame and raise truck. • Carefully remove blocks and lower truck. • Remove jack and blocks from drive wheels.
SM 616, April ’98 SA-2-4 • Lifting, Jacking, and Blocking Group SA, Safe Maintenance CAUTION Before performing any maintenance work, check the truck for stable condition on the blocking. 7. When maintenance work is completed, lower the en- tire truck to the floor by reversing this procedure. Lower the truck one side at a time, while carefully removingtheblocks. Besurenotoolsorequipmentare under the truck or wheels. NOTE Depending on jack height, shims under the tires may be needed for clearance to allow removal of jack. Shipping Tie-Down Instructions 1. Front of Truck a. With Upright and Carriage Installed • Lower the carriage fully. • Put a tie-down (e.g., chain) between the carriage fork bars. b. Without Upright and Carriage Installed • Put a chain across the truck floor plate. Protect truck from chain damage by using covered chain or protective material under the chain at contact points. 2. Rear of Truck • Attach the tie-down to the toe-pin in top of coun- terweight. Raising Entire Truck Refer to truck data plate for truck weights. 1. Park truck safely. Lower upright fully. If necessary, drive truck onto boards to increase under-clearance. WARNING SIDE-TO-SIDE TIPOVER. When jacking side of truck, be sure upright is lowered fully. Do not raise one side of the truck more than about 50 mm (2 in) higher than the other, to avoid tipping truck over laterally. END-TO-END TIPOVER. If the upright and drive axle are removed while the truck is blocked up, the truck will tip backward due to the heavy counterweight. Upright and counterweight must both be removed before attempting to raise the truck for drive axle removal. The back of the truck must be supported by blocking under the steer axle to prevent movement. Ifthecounterweightisremovedwhilethetruck is up on blocks, the weight of the upright and drive axle will cause the truck to fall forward. 2. Putthejackundersideframe,nearthecenterofthetruck. IMPORTANT Be sure to put the jack squarely and fully under the main side structure of the frame. 3. Carefullyraisethetruckonesideatatime,onlyashigh asnecessarytodothemaintenancework,andnotmore than 150 mm (6 in) total. 4. Putblocksunderthesideframe,ateachsideofthejack. Spread the blocks close to the steer and drive wheels for maximum stability. 5. If using one jack, lower the truck onto the blocks and move the jack to the opposite side. Repeat the lifting procedure. 6. Put the same size blocks under each side of the truck so it will be leveled.
SM 616, April ’98 Brake Specifications • 23-1-1 Group 23, Brakes Section 1. Brake Specifications and Description Specifications Service Brake: Type: Caliper. Minimum lining/pad thickness: 0.67 mm (0.06 in). Fluid Type: SAEJ1703 (DOT-3) brake fluid only. Fluid Capacity: 0.256 L (0.06 gal). Pedal Freeplay: 1-3 mm (0.039-0.118 in; measured at stop screw). Parking Brake: Type: Lever-type mechanically linked to brake assembly. Holding Test: Rated load on 15% grade. Service Requirements Operational checks and inspection of linkages, brake pads, and brake lines are specified in the Periodic Service Chart in Group PS. Service brake linkage adjustment and lube are not normally required. Brake pads are self-adjusting. A leaking caliper or master cylinder should be overhauled or replaced. Parking brake should be adjusted if indicated by opera- tional check. The following sections in this Group provide service proce- dures for the service and parking brake assemblies. Description (See illustration on the next page.) The service brake pedal operates a master cylinder mounted on the front cowl. The master cylinder operates a caliper assembly centrally mounted on the two drive axle housings. When the caliper assembly is activated, its pads grip the brake discs mounted on the inboard end of each drive axle pinion shaft. Friction betwen the pads and disks slows or stops rotation of the drive axle. There is no power assist for the service brake. The parking brake handle operates a ratchet and cable that closes or releases the caliper assembly. See Group 20,“”Drive Axle,” for more detail.
SM 616, April ’98 23-1-2 • Brake Specifications Group 23, Brakes Brake Caliper and Brake Lines Installation to Drive Axle Parking Brake and Linkage to Brake Caliper Reservoir, Pedal, Master Cylinder and Linkage
Brake Bleeding • 23-2-1 Group 23. Brakes SM 616, April ’98 Section 2. Fluid Check, Fill, and Bleed Bleeding Bleed brakes when: • The brake pedal feels spongy or low. • The master cylinder, caliper, or brake lines have been leaking, repaired, or replaced. • Troubleshootingindicatesthatairhasbeenintroduced into the system. Proceed as follows: 1. Park truck on level floor. Put direction control in neutral. Lower forks to floor, tilt forward, and apply parking brake. 2. Attach a clear hose to a bleed screw on the brake caliper. Place the other end of the hose in a vessel containing fluid. 3. Fill the brake fluid reservoir. 4. Open the bleed screw. 5. Pump the brake pedal until the fluid flowing from the hose is free of bubbles. 6. Continue pumping the brakes and tighten the bleed screw. 7. Repeat for the other caliper bleed screw. 8. Operate the brake pedal at various rates. If the pedal feels spongy or low, bleed the lines again. 9. Refill the master cylinder to the full mark. Bleed Screw Bleed Screw Clear Bleeder Hose Check and Fill Inspect brake fluid level in reservoir through window in left cowl cover. A flashlight may be needed. If fluid level is below full mark, remove cowl cover as described in Group 38 and fill reservoir to full mark with DOT 3 fluid. Reservoir Window NOTE Make sure that brake pedal freeplay is correctly set be- fore bleeding the brakes.
SM 616, April ’98 Pedal and Master Cylinder R&R and Adjustment • 23-3-1 Group 23, Brakes Section 3. Pedal and Master Cylinder Removal, Replacement, and Adjustment
SM 616, April ’98 23-3-2 • Pedal and Master Cylinder R&R and Adjustment Group 23, Brakes Components Disassembly Use Figures 1, 2, and 3 as guide to disassembly and adjust- ment. Components Reassembly Replace the brake pedal components as shown in Figures 1 and 2 using fastener torques where shown. Also use the following notes: 1. Clean the reservoir and master cylinder hoses and fittings. Make sure no contaminants enter the braking system. 2. Adjust pedal free play and micro-switch as described in “Pedal Adjustment” on this page. 3. After re-assembly and adjustment, the brake system must be bled; see Section 2 in this Group. After bleeding, check all fluid connections for leaks and test brakes completely before returning truck to service. 4. Note orientation of pedal spring. Upper (shorter) end catchesincowlbracket.Lower(longer)endcatcheson pin in link. Pedal Adjustment With all components replaced and fasteners tightened to correct torque, adjust the pedal as follows: 1. Adjust pedal stop screw (item F) to provide 1-3 mm (0.04-0.12 in) of free play. 2. When free play is adjusted, tighten the jam nut on the stop screw to set the distance. 3. Adjust micro-switch to activate just before end of pedal free play. See Group 13 for brake switch check and adjustments.
SM 616, April ’98 Pedal and Master Cylinder R&R and Adjustment • 23-3-3 Group 23, Brakes See Figure 2 for Larger View See Figure 3 for Larger View Figure 1. Reservoir, Pedal, Linkage, and Master Cylinder Assembly. B F D I J G E H C A Hose to Master Cylinder B Reservoir C Brackets Welded to Cowl D Pedal E Pedal Spring F Stop Screw G Pedal Link H Master Cylinder Link I Master Cylinder J Fitting to Brake Caliper Line Torque: 8-10 N•m (71-88 in-lb) A Torque: 20-25 N•m (177-221 in-lb) (4 fasteners) Torque: 40-45 N•m (30-33 ft-lb) Torque: 20-25 N•m (177-221 in-lb)
SM 616, April ’98 23-3-4 • Pedal and Master Cylinder R&R and Adjustment Group 23, Brakes Figure 2. Upper Area of Figure 1 Enlarged
SM 616, April ’98 Pedal and Master Cylinder R&R and Adjustment • 23-3-5 Group 23, Brakes Figure 3. Lower Area of Figure 1 Enlarged
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SM 616, April ’98 Brake Caliper Removal and Replacement • 23-4-1 Group 23, Brake Section 4. Brake Caliper Removal and Replacement
SM 616, April ’98 23-4-2 • Brake Caliper Removal and Replacement Group 23, Brake Introduction Figures 1 and 2 show: • The brake mounting on the drive axle. • The connections from the master cylinder to the brake. The illustrations and accompanying text serve as a guide to removal and replacement. Before beginning this service procedure: • Park the truck on a level surface and lower the upright completely. • Raise and block the upright for better access as de- scribed in Group SA. • Return all controls to neutral and turn key switch to OFF position. • Block the wheels. See Section 3 for procedures to remove brake pedal and master cylinder. See Section 6 for brake overhaul proce- dures. Brake Removal 1. Disconnect tube assemblies from brake at the com- pressionfittingsshowninFigure2.Movetubingoutof the way; disconnect from the tee if necessary. 2. Remove the cotter pin from the parking brake caliper clevis (see Section 5). 3. Remove bolts and washers from brake mounting bracket. Lift the caliper assembly from the transaxle. 4. To remove the brake rotors: a. Slide the left-side rotor off of the splined shaft and lift out. b. Repeat for opposite rotor. c. Inspect axle seals per procedures in Group Transaxle. Replace if worn, leaking, or damaged. Brake Replacement. 1. To replace rotors: a. Coat splines of brake rotor with an anti-seize compound before installing in truck. b. Grasp rotor around the outer edge and line up with the spline. c. Push rotor onto splined shaft until it is fully engaged. d. Repeat for opposite rotor. Both rotors should be free to float on the splines. 2. Replace brake as shown in Figure 1: a. Mount brake over disk. b. Set mounting bolts in place and torque to 0.5-2 N•m (0.4-1.5 ft-lb). c. Replace tube assemblies at the compression fit- tings. Do not overtighten. d. Press brake pedal to align brake and disk. e. Torque mounting bolts to 60-65 N•m (44-48 ft- lb). 3. Replace rear cover. Torque top bolts to 60-65 N•m (44-48 ft-lb); torque bottom nut to 170-190 N•m (125- 140 ft-lb). IMPORTANT Both sides of brake must be checked and fully refilled with proper lubricant. See brake bleeding Section in this Group.
SM 616, April ’98 Brake Caliper Removal and Replacement • 23-4-3 Group 23, Brake Figure 1. Brake Mounting Figure 2. Brake Tubing Connections Tube Assembly Compression Fitting Brake Rotors Front Cover Rear Cover Caliper Assembly Drive Axle Assembly Brake Disks Torque: 60-65 N•m (44-48 ft-lb) Torque: 170-190 N•m (125-140 ft-lb)

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  • 1. #40–1, Ungnam-Dong, Changwon-City,Kyungnam, Korea TMG 12-25 TMG13-20X EPG 15-18 Part No. 8026067 Book No. SM-616 REV.2 Dec. 2002 SERVICE MANUAL TMG 12-25 RATED CAPACITY: 1250 – 2270KG EPG 15-18 RATED CAPACITY: 1500 – 1800KG Manufactured by
  • 2. Contents-ii SM 616, Sep ’02 © Copyright Clark Material Handling Company 2001 This manual is intended for the use of trained service personnel. Please read Group SA, “Safe Maintenance,” and the Operator’s Manual before working on or operat- ing the truck. Page ID Manual ID Group ID Page ID Group ID Section ID Section ID Arrangement and Use of this Manual Clark arranges parts and service procedures by standard- ized Groups. In this manual, Groups are similar to “Chap- ter.” Groups are listed I the table of contents on the next page. Each Group begins with a table of contents that shows the Sections contained within the Group. Lengthy Sections also begin with a table of contents showing the topics contained within the Section. Each Group and Section has an identifying name and number, or “ID.” Each page also has a unique ID. The page ID consists of three numbers separated by hyphens, year/month and the revision number. The three numbers represent the Group number, the Section number, and the page number. For example, “00-1-2” on the lower corner of the page indi- cates Group 00, Section 1, Page 2. The year/month repre- sent the issued or revised one such as April 98. The revision number indicates the revised frequency such as ➀, ➁ .... If not depicted, the page has not been revised. You can quickly locate a specific point in the manual by using the headers and footers that appear on every Sec- tion page. The following illustration points out these areas.
  • 3. Contents-iii SM 616, April ’98 SA SAFE MAINTENANCE 1. Safety 2. Lifting, Jacking, and Blocking 3. Towing PS PERIODIC SERVICE 1. Maintenance Schedules 2. Planned Maintenance 3. PM Inspection Form 12 BATTERY 1. Battery Service 13 WIRING, SWITCHES, AND INSTRUMENTS 1. Schematic Diagrams 2. General Electrical Service Tips 3. Wiring and Cables 4. Switches and Sensors 5. Instrument Panel 16 ELECTRIC MOTORS 1. Specifications and Description 2. Troubleshooting 3. Drive Motors Overhaul 4. Lift Pump Motor Overhaul 5. Steering Pump Motor Overhaul 17 CONTACTORS 1. Specifications and Overhaul 19 MOTOR CONTROLS 1. Specifications and Description 2. Sequence of Operations 3. Handset Operation 4. Diagnostic Status Codes 5. Controllers Removal and Replacement 20 DRIVE AXLE 1. Specifications and Description 2. Fluid Check and Change 3. Troubleshooting 4. Drive Axle Removal and Installation 5. Drive Axle Overhaul 22 WHEELS AND TIRES 1. Specifications and Description 2. Wheels & Tires Mounting and Maintenance 23 BRAKE SYSTEM 1. Specifications and Description 2. Fluid Check, Fill, and Bleed 3. Pedal and Master Cylinder Removal, Replace- ment, and Adjustment 4. Brake Removal and Replacement 5. Parking Brake R&R and Adjustment 6. Brake Overhaul 25/26 STEER SYSTEM 1. Specifications and Description 2. Troubleshooting 3. Column Removal and Replacement 4. Relief Pressure Check and Adjustment 5. Steering Gear Overhaul 6. Steer Axle Service 7. Steer Cylinder Overhaul 8. Steer Pump Overhaul 29/30 HYDRAULIC SYSTEM 1. Specifications and Description 2. Fluids and Filters 3. Troubleshooting 4. Pressure Checks and Adjustments 5. Main Pump Removal and Overhaul 6. Main Control Valve Removal and Overhaul 32 TILT CYLINDERS 1. Specifications and Description 2. Checks and Adjustments 3. Removal and Installation 4. Overhaul 34 UPRIGHTS 1. Upright Specifications and Description 2. Trouble shooting 3. Upright Inspection 4. Carriage and Upright Roller Clearance Checks and Shim Adjustment 5. Cylinder Removal, Shimming, Overhaul and Replacement 6. Upright Chain Inspection, Adjustment and Installation 7. Fork and Carriage Removal and Installation 8. Upright Removal and Replacement 38 COUNTERWEIGHT AND CHASSIS 1. Specifications and Description 2. Counterweight Removal and Installation 3. Overhead Guard Removal and Installation 4. Floor Plate, Seat, and Seat Deck R&R 40 SPECIFICATIONS 1. Nameplate and Decals 2. Specifications 3. Hydraulic Fitting Tightening Procedure Contents by Group and Section Contents are listed here by Group number and name followed by Section number and name: CONTENTS (Alphabetical listing of contents appears on next page.)
  • 4. Contents-iv SM 616, April ’98 Battery Service ......................................................... 12-1 Brake Fluid Check, Fill, and Bleed ......................... 23-2 Brake Overhaul ........................................................ 23-6 Brake Removal and Replacement .......................... 23-4 Brake System Specifications and Description ...... 23-1 Carriage and Upright Roller Clearance Checks and Shim Adjustments.................................................... 34-1 Column Removal and Replacement .................. 25/26-3 Contactors ................................................................ 17-1 Contactors Specifications and Description .......... 17-1 Controllers Removal and Replacement ................. 19-5 Controllers Specifications and Description .......... 19-1 Counterweight Removal and Installation............... 38-2 Counterweight Specifications and Description .... 38-1 Cylinder Removal, Shimming, Overhaul, and Replacement ............................................................. 34-5 Diagnostic Status Codes ......................................... 19-4 Drive Axle Fluid Check and Change ...................... 20-2 Drive Axle Overhaul ................................................. 20-5 Drive Axle Removal and Installation ...................... 20-4 Drive Axle Specifications and Description ............ 20-1 Drive Axle Troubleshooting .................................... 20-3 Drive Motors Overhaul ............................................ 16-3 Electrical Service Tips ............................................. 13-2 Floor Plate Removal and Replacement .................. 38-4 Fork and Carriage Removal and Installation ......... 34-7 Handset Operation ................................................... 19-3 Hydraulic Control Valve Overhaul .....................29/30-6 Hydraulic Fitting Tightening Procedure................. 40-3 Hydraulic Fluids and Filters ............................... 29/30-2 Hydraulic Pressure Checks and Adjustments . 29/30-4 Hydraulic Lift Pump Overhaul............................29/30-5 Hydraulic Specifications and Description ........29/30-1 Hydraulic System Troubleshooting................... 29/30-3 Instrument Panel ...................................................... 13-5 Jacking and Blocking ............................................. SA-2 Lift Chain Inspection and Service Guidelines ....... 34-2 Lift Pump Motor Overhaul ....................................... 16-4 Maintenance Schedules ........................................ PM-1 Motors Specifications and Description ................. 16-1 Motors Troubleshooting .......................................... 16-2 Nameplate and Decals ............................................. 40-1 Overhead Guard Removal and Installation ........... 38-3 Parking Brake R&R and Adjustment ...................... 23-5 Pedal and Master Cylinder R&R and Adjustment . 23-3 Planned Maintenance ............................................ PM-2 PM Inspection Form ............................................... PM-3 Safety ....................................................................... SA-1 Schematic Electrical Diagrams ............................... 13-1 Seat and Seat Deck Removal and Replacement ... 38-4 Sequence of Operations .......................................... 19-2 Specifications and Description ......................... 25/26-1 Specifications for Entire Truck ............................... 40-2 Steer Axle Service ...............................................25/26-6 Steer Cylinder Overhaul ..................................... 25/26-7 Steer Pump Overhaul .........................................25/26-8 Steering Gear (Valve) Overhaul ......................... 25/26-5 Steering Pump Motor Overhaul .............................. 16-5 Steering Relief Pressure Check and Adjust ..... 25/26-4 Switches and Sensors ............................................. 13-4 Tilt Cylinders Checks and Adjustments ................ 32-2 Tilt Cylinders Overhaul ............................................ 32-4 Tilt Cylinders Removal and Installation ................. 32-3 Tilt Cylinders Specifications and Description ....... 32-1 Towing...................................................................... SA-3 Troubleshooting ......................................... 25/26-2/34-2 Upright Chain Inspection, Adjustment and Installation ......................................................... 34-6 Upright Inspection ................................................... 34-3 Upright Removal and Replacement ....................... 34-8 Upright Specifications and Description ................. 34-1 Wheels & Tires Mounting and Maintenance .......... 22-1 Wheels & Tires Specifications and Description .... 22-1 Wiring and Cables .................................................... 13-3 Alphabetical Listing of Topics (Contents are listed by order of Group and Section numbers on previous page.) Contents are listed here by topic followed by the Group#-Section# the topic appears in:
  • 5. GROUP SA Safe Maintenance SM 616, April ’98 Safety ............................................................................... Section 1 Lifting, Jacking, and Blocking the Truck ..................... Section 2 Towing.............................................................................. Section 3 GROUP SA SAFE MAINTENANCE
  • 6. SM 616, April ’98 Safety • SA-1-1 Group SA, Safe Maintenance Section 1. Safety Safety Signs and Messages Safety signs and messages in this manual and on the lift truck provide instructions and identify specific areas where potential hazards exist and special precautions should be taken. Be sure you know and understand the meaning of these instructions, signs, and messages. Damage to the truck, death, or serious injury to you or other persons may result if these messages are not followed. NOTE This message is used when special informa- tion, instructions or identification is re- quired relating to procedures, equipment, tools, pressures, capacities, and other spe- cial data. IMPORTANT This message is used when special precau- tions should be taken to ensure a correct action or to avoid damage to, or malfunc- tion of, the truck or a component. CAUTION This message is used as a reminder of safety hazards that can result in personal injury if proper precautions are not taken. WARNING This message is used when a hazard exists that can result in injury or death if proper precautions are not taken. DANGER This message is used when an extreme haz- ard exists that can result in injury or death or serious injury if proper precautions are not taken. The above terms have been adopted by Clark Material Handling Company. The same terms may be used in differ- ent context in service literature supplied directly or indi- rectly by vendors of truck components. Safe Maintenance Practices The following instructions have been prepared from cur- rent industry and government safety standards applicable to industrial truck operation and maintenance. These rec- ommended procedures specify conditions, methods, and accepted practices that aid in the safe maintenance of in- dustrial trucks. They are listed here for the reference and safety of all workers during maintenance operations. Care- fully read and understand these instructions and the spe- cific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please con- tact your local Clark dealer. 1. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable mainte- nance facilities, trained personnel, and procedures must be provided. 2. Maintenance and inspection of all powered industrial trucks shall be done in conformance with the manufacturer’s recommendations. 3. A scheduled planned maintenance, lubrication, and inspection program shall be followed. 4. Only trained and authorized personnel shall be permit- ted to maintain, repair, adjust, and inspect industrial trucks. Work should be performed in accordance with the manufacturer’s specifications. 5. Properly ventilate work area, vent exhaust fumes, and keep shop clean and floor dry. 6. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check for level or leakage of fuel, electrolyte, oil, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Before starting work on truck: a. Raise drive wheels off of floor and use blocks or other positive truck positioning devices. b. Disconnect battery before working on the electri- cal system. 8. Before working on engine fuel system of gasoline- or diesel-powered trucks, be sure the fuel shut-off valve is closed. 9. Operation of the truck to check performance must be
  • 7. SM 616, Jul ’01 SA-1-2 • Safety Group SA, Safe Maintenance conducted in an authorized, safe, clear area. 10. Before starting to drive truck: a. Be in operating position with seat belt fastened. b. Be sure parking brake is engaged. c. Put direction control in neutral. d. Start engine. e. Check functioning of direction and speed con- trols, steering, brakes, warning devices, and any load handling attachments. 11. Before leaving truck a. Stop truck. b. Put directional control in neutral. c. Apply the parking brake. d. Stop the engine by turning off the key switch. e. Put upright in vertical position and fully lower the forks or attachment. f. Put blocks at the wheels if truck is on an incline. 12. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, guards, safety de- vices, and frame members must be carefully and regu- larly inspected and maintained in a safe operating condition. 13. Special trucks or devices designed and approved for hazardous area operation must receive special atten- tion to ensure that maintenance preserves the original, approved, safe-operating features. 14. Fuel systems must be checked for leaks and condition of parts. Extra special consideration must be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the truck until the leak has been corrected. 15. The truck manufacturer’s capacity, operation, and maintenance instruction plates, tags, or decals must be maintained in legible condition. 16. Batteries, motors, controllers, limit switches, protec- tive devices, electrical conductors, and connections must be inspected and maintained in conformance with good practice. Special attention must be paid to the condition of electrical insulation. 17. To avoid injury to personnel or damage to the equip- ment,consultthemanufacturer’sproceduresinreplac- ing contacts on any battery connection. 18. Industrial trucks must be kept in a clean condition to minimizefirehazardsandhelpinthedetectionofloose or defective parts. 19. Modifications and additions that affect capacity and safe truck operation must not be done without the manufacturer’s prior written approval. Capacity, op- eration and maintenance instruction plates, tags, or decals must be changed accordingly. This is an OSHA requirement. 20. Care must be taken to assure that all replacement parts, including tires, are interchangeable with the original parts and of a quality at least equal to that provided in the original equipment. Parts, including tires, are to be installed per the manufacturer’s procedures. Always use genuine CLARK or CLARK-approved parts. 21. Use special care when removing heavy components from the truck, such as counterweight, seat deck, upright, etc. Be sure that lifting and handling equip- ment is of the correct capacity and in good condition. Also, this removal may upset the stability of the truck. The frame must always be safely blocked for major component removal. NOTE You should also be familiar with additional operating and maintenance safety instruc- tions contained in the following publica- tions: ASME B56.1 - 1988: Operator Control-Industrial Tow Trac- tors (Safety Standard For Powered Industrial Trucks). Pub- lished by: American Society of Mechanical Engineers, Three Park Avenue, New York, NY10016. NFPA 505-1982: Fire Safety Standard for Powered Indus- trial Trucks: Type Designations, Areas of Use, Mainte- nance and Operation. Available from: National Fire Protection Assoc., Inc., Batterymarch Park, Quincy, MA 02269. General Industrial Standards, OSHA 2206: OSHA Safety and Health Standards (29 CFR 1910), Subpart N-Materials Handling and Storage, Section 1910.178 Powered Indus- trial Trucks. For sale by: Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402.
  • 8. SM 616, April ’98 Lifting, Jacking, and Blocking • SA-2-1 Group SA, Safe Maintenance Section 2. Lifting, Jacking, and Blocking WARNING Lifting or jacking any large piece of equipment such as a fork truck presents obvious hazards. It must be done with great care and fore- thought. Consult the truck weight information in Group 40, Specifica- tions, to ensure that your lifting equipment is of adequate capacity. Raising Drive Wheels.....................................................................................................................2 Chaining the Upright in Raised Position .....................................................................................2 Raising Rear of Truck ...................................................................................................................3 Raising Entire Truck .....................................................................................................................4 Shipping Tie-Down Instructions...................................................................................................4
  • 9. SM 616, April ’98 SA-2-2 • Lifting, Jacking, and Blocking Group SA, Safe Maintenance CAUTION To perform these service procedures, first: • Park truck on a level surface. • Put the upright in a vertical position and lower the carriage fully down. • Return control handle to neutral and turn key switch OFF. WARNING Defective equipment can cause accidents. All tools and lifting equipment must be in good condition, meet the load capacity requirements and have OSHA labels when required. Tools with defects can fail, causing severe injury or death. Raising Drive Wheels This procedure uses the upright to lift the drive wheels off the floor. 1. Park the truck safely. 2. Turn key switch ON. Tilt the upright fully back. 3. Put a solid 100 x 100 mm (4 x 4 inch) hardwood block under the front section of each upright rail. Put a 3–6 mm (0.125–0.250 inch) steel plate on top of each block. 4. Tilt the upright fully forward. This will raise the drive wheels off the floor. 5. Block the truck under the frame behind the drive wheels with solid blocking. 6. Turn key switch OFF. Blocking a Typical Upright 7. Check for safe clearance between drive wheels, block and floor. 8. Check the stability of the truck. Be sure that the blocks are located securely under the frame before operating the drive motor or working on truck. 9. Lower the drive wheels to the floor by reversing this procedure. • Turn key switch ON. • Tilt upright fully back. • Turn key switch OFF. 10. Remove the blocks from under the frame and upright rails. Chaining the Upright in Raised Position This procedure provides safe clearance for access from the front of truck to components on or near the drive axle. 1. Park truck safely. 2. Put blocks at front of and rear of drive wheels. 3. Raise upright carriage. 4. Chainthecenterinnerrailtiebartothetopouterrailtie bar as shown. Triple Stage Uprights: Chain the center intermediate rail tie bar and the lower inner rail tie bar to the top outer rail tie bar. 5. Reverse the procedure to remove the chains. WARNING Keep hands, tools, etc. out of upright.
  • 10. SM 616, April ’98 Lifting, Jacking, and Blocking • SA-2-3 Group SA, Safe Maintenance Raising Rear of Truck The truck may be raised at the rear by jacking and blocking under the frame just beyond the counterweight.. Refer to truck data plate for truck weights. WARNING An incorrectly installed counterweight can move or fall unexpectedly. NEVER LIFT OR BLOCK A TRUCK USING THE COUNTERWEIGHT. Failure to follow procedures outlined in this manual can result in injury or death. 1. Park truck safely. 2. Put blocks at front and rear of drive wheels. CAUTION If possible, remove the battery from truck to reduce weight for added safety and ease of jacking. 3. Put a floor jack under the frame just beyond the counterweight. WARNING Never lift the truck by the counterweight. NOTE If there is insufficient clearance under frame for your jack, the truck may first be driven onto shims, such as 25 x 150 x 300 mm (1 x 6 x 12 in) pieces of board, to increase the truck frame under-clearance. 4. Jack up one side of the truck about 50 mm (2 in) and putablockundertheframetoholdthatelevation.Then move the jack to the other side and jack and block it. Continue to alternate the procedure from side to side, increasing elevation not more than 50 mm (2 in) each time. Raise the truck no higher than necessary to perform the maintenance work. Makesuretheleftandrightsidesofthetruckarefinally blocked in a level working position. CAUTION Before performing any maintenance work, check the truck for stable condition on the blocking by determining that it will not rock on blocks. 5. When maintenance work is completed, lower the rear of truck to the floor by reversing the above procedure and lowering each side of the truck 50 mm (2 in) at a time: • Put jack under frame and raise truck. • Carefully remove blocks and lower truck. • Remove jack and blocks from drive wheels.
  • 11. SM 616, April ’98 SA-2-4 • Lifting, Jacking, and Blocking Group SA, Safe Maintenance CAUTION Before performing any maintenance work, check the truck for stable condition on the blocking. 7. When maintenance work is completed, lower the en- tire truck to the floor by reversing this procedure. Lower the truck one side at a time, while carefully removingtheblocks. Besurenotoolsorequipmentare under the truck or wheels. NOTE Depending on jack height, shims under the tires may be needed for clearance to allow removal of jack. Shipping Tie-Down Instructions 1. Front of Truck a. With Upright and Carriage Installed • Lower the carriage fully. • Put a tie-down (e.g., chain) between the carriage fork bars. b. Without Upright and Carriage Installed • Put a chain across the truck floor plate. Protect truck from chain damage by using covered chain or protective material under the chain at contact points. 2. Rear of Truck • Attach the tie-down to the toe-pin in top of coun- terweight. Raising Entire Truck Refer to truck data plate for truck weights. 1. Park truck safely. Lower upright fully. If necessary, drive truck onto boards to increase under-clearance. WARNING SIDE-TO-SIDE TIPOVER. When jacking side of truck, be sure upright is lowered fully. Do not raise one side of the truck more than about 50 mm (2 in) higher than the other, to avoid tipping truck over laterally. END-TO-END TIPOVER. If the upright and drive axle are removed while the truck is blocked up, the truck will tip backward due to the heavy counterweight. Upright and counterweight must both be removed before attempting to raise the truck for drive axle removal. The back of the truck must be supported by blocking under the steer axle to prevent movement. Ifthecounterweightisremovedwhilethetruck is up on blocks, the weight of the upright and drive axle will cause the truck to fall forward. 2. Putthejackundersideframe,nearthecenterofthetruck. IMPORTANT Be sure to put the jack squarely and fully under the main side structure of the frame. 3. Carefullyraisethetruckonesideatatime,onlyashigh asnecessarytodothemaintenancework,andnotmore than 150 mm (6 in) total. 4. Putblocksunderthesideframe,ateachsideofthejack. Spread the blocks close to the steer and drive wheels for maximum stability. 5. If using one jack, lower the truck onto the blocks and move the jack to the opposite side. Repeat the lifting procedure. 6. Put the same size blocks under each side of the truck so it will be leveled.
  • 12. SM 616, April ’98 Brake Specifications • 23-1-1 Group 23, Brakes Section 1. Brake Specifications and Description Specifications Service Brake: Type: Caliper. Minimum lining/pad thickness: 0.67 mm (0.06 in). Fluid Type: SAEJ1703 (DOT-3) brake fluid only. Fluid Capacity: 0.256 L (0.06 gal). Pedal Freeplay: 1-3 mm (0.039-0.118 in; measured at stop screw). Parking Brake: Type: Lever-type mechanically linked to brake assembly. Holding Test: Rated load on 15% grade. Service Requirements Operational checks and inspection of linkages, brake pads, and brake lines are specified in the Periodic Service Chart in Group PS. Service brake linkage adjustment and lube are not normally required. Brake pads are self-adjusting. A leaking caliper or master cylinder should be overhauled or replaced. Parking brake should be adjusted if indicated by opera- tional check. The following sections in this Group provide service proce- dures for the service and parking brake assemblies. Description (See illustration on the next page.) The service brake pedal operates a master cylinder mounted on the front cowl. The master cylinder operates a caliper assembly centrally mounted on the two drive axle housings. When the caliper assembly is activated, its pads grip the brake discs mounted on the inboard end of each drive axle pinion shaft. Friction betwen the pads and disks slows or stops rotation of the drive axle. There is no power assist for the service brake. The parking brake handle operates a ratchet and cable that closes or releases the caliper assembly. See Group 20,“”Drive Axle,” for more detail.
  • 13. SM 616, April ’98 23-1-2 • Brake Specifications Group 23, Brakes Brake Caliper and Brake Lines Installation to Drive Axle Parking Brake and Linkage to Brake Caliper Reservoir, Pedal, Master Cylinder and Linkage
  • 14. Brake Bleeding • 23-2-1 Group 23. Brakes SM 616, April ’98 Section 2. Fluid Check, Fill, and Bleed Bleeding Bleed brakes when: • The brake pedal feels spongy or low. • The master cylinder, caliper, or brake lines have been leaking, repaired, or replaced. • Troubleshootingindicatesthatairhasbeenintroduced into the system. Proceed as follows: 1. Park truck on level floor. Put direction control in neutral. Lower forks to floor, tilt forward, and apply parking brake. 2. Attach a clear hose to a bleed screw on the brake caliper. Place the other end of the hose in a vessel containing fluid. 3. Fill the brake fluid reservoir. 4. Open the bleed screw. 5. Pump the brake pedal until the fluid flowing from the hose is free of bubbles. 6. Continue pumping the brakes and tighten the bleed screw. 7. Repeat for the other caliper bleed screw. 8. Operate the brake pedal at various rates. If the pedal feels spongy or low, bleed the lines again. 9. Refill the master cylinder to the full mark. Bleed Screw Bleed Screw Clear Bleeder Hose Check and Fill Inspect brake fluid level in reservoir through window in left cowl cover. A flashlight may be needed. If fluid level is below full mark, remove cowl cover as described in Group 38 and fill reservoir to full mark with DOT 3 fluid. Reservoir Window NOTE Make sure that brake pedal freeplay is correctly set be- fore bleeding the brakes.
  • 15. SM 616, April ’98 Pedal and Master Cylinder R&R and Adjustment • 23-3-1 Group 23, Brakes Section 3. Pedal and Master Cylinder Removal, Replacement, and Adjustment
  • 16. SM 616, April ’98 23-3-2 • Pedal and Master Cylinder R&R and Adjustment Group 23, Brakes Components Disassembly Use Figures 1, 2, and 3 as guide to disassembly and adjust- ment. Components Reassembly Replace the brake pedal components as shown in Figures 1 and 2 using fastener torques where shown. Also use the following notes: 1. Clean the reservoir and master cylinder hoses and fittings. Make sure no contaminants enter the braking system. 2. Adjust pedal free play and micro-switch as described in “Pedal Adjustment” on this page. 3. After re-assembly and adjustment, the brake system must be bled; see Section 2 in this Group. After bleeding, check all fluid connections for leaks and test brakes completely before returning truck to service. 4. Note orientation of pedal spring. Upper (shorter) end catchesincowlbracket.Lower(longer)endcatcheson pin in link. Pedal Adjustment With all components replaced and fasteners tightened to correct torque, adjust the pedal as follows: 1. Adjust pedal stop screw (item F) to provide 1-3 mm (0.04-0.12 in) of free play. 2. When free play is adjusted, tighten the jam nut on the stop screw to set the distance. 3. Adjust micro-switch to activate just before end of pedal free play. See Group 13 for brake switch check and adjustments.
  • 17. SM 616, April ’98 Pedal and Master Cylinder R&R and Adjustment • 23-3-3 Group 23, Brakes See Figure 2 for Larger View See Figure 3 for Larger View Figure 1. Reservoir, Pedal, Linkage, and Master Cylinder Assembly. B F D I J G E H C A Hose to Master Cylinder B Reservoir C Brackets Welded to Cowl D Pedal E Pedal Spring F Stop Screw G Pedal Link H Master Cylinder Link I Master Cylinder J Fitting to Brake Caliper Line Torque: 8-10 N•m (71-88 in-lb) A Torque: 20-25 N•m (177-221 in-lb) (4 fasteners) Torque: 40-45 N•m (30-33 ft-lb) Torque: 20-25 N•m (177-221 in-lb)
  • 18. SM 616, April ’98 23-3-4 • Pedal and Master Cylinder R&R and Adjustment Group 23, Brakes Figure 2. Upper Area of Figure 1 Enlarged
  • 19. SM 616, April ’98 Pedal and Master Cylinder R&R and Adjustment • 23-3-5 Group 23, Brakes Figure 3. Lower Area of Figure 1 Enlarged
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  • 21. SM 616, April ’98 Brake Caliper Removal and Replacement • 23-4-1 Group 23, Brake Section 4. Brake Caliper Removal and Replacement
  • 22. SM 616, April ’98 23-4-2 • Brake Caliper Removal and Replacement Group 23, Brake Introduction Figures 1 and 2 show: • The brake mounting on the drive axle. • The connections from the master cylinder to the brake. The illustrations and accompanying text serve as a guide to removal and replacement. Before beginning this service procedure: • Park the truck on a level surface and lower the upright completely. • Raise and block the upright for better access as de- scribed in Group SA. • Return all controls to neutral and turn key switch to OFF position. • Block the wheels. See Section 3 for procedures to remove brake pedal and master cylinder. See Section 6 for brake overhaul proce- dures. Brake Removal 1. Disconnect tube assemblies from brake at the com- pressionfittingsshowninFigure2.Movetubingoutof the way; disconnect from the tee if necessary. 2. Remove the cotter pin from the parking brake caliper clevis (see Section 5). 3. Remove bolts and washers from brake mounting bracket. Lift the caliper assembly from the transaxle. 4. To remove the brake rotors: a. Slide the left-side rotor off of the splined shaft and lift out. b. Repeat for opposite rotor. c. Inspect axle seals per procedures in Group Transaxle. Replace if worn, leaking, or damaged. Brake Replacement. 1. To replace rotors: a. Coat splines of brake rotor with an anti-seize compound before installing in truck. b. Grasp rotor around the outer edge and line up with the spline. c. Push rotor onto splined shaft until it is fully engaged. d. Repeat for opposite rotor. Both rotors should be free to float on the splines. 2. Replace brake as shown in Figure 1: a. Mount brake over disk. b. Set mounting bolts in place and torque to 0.5-2 N•m (0.4-1.5 ft-lb). c. Replace tube assemblies at the compression fit- tings. Do not overtighten. d. Press brake pedal to align brake and disk. e. Torque mounting bolts to 60-65 N•m (44-48 ft- lb). 3. Replace rear cover. Torque top bolts to 60-65 N•m (44-48 ft-lb); torque bottom nut to 170-190 N•m (125- 140 ft-lb). IMPORTANT Both sides of brake must be checked and fully refilled with proper lubricant. See brake bleeding Section in this Group.
  • 23. SM 616, April ’98 Brake Caliper Removal and Replacement • 23-4-3 Group 23, Brake Figure 1. Brake Mounting Figure 2. Brake Tubing Connections Tube Assembly Compression Fitting Brake Rotors Front Cover Rear Cover Caliper Assembly Drive Axle Assembly Brake Disks Torque: 60-65 N•m (44-48 ft-lb) Torque: 170-190 N•m (125-140 ft-lb)